Device for communicating with a system

ABSTRACT

A device for communicating with a system, especially for operating and monitoring an automated industrial manufacturing system is described. The device contains a mobile communication device for wireless exchange of data with the system. Further, the device also includes a fixed installed connection for the communication device and a sensor recognizing whether the communication device is connected to the fixed installed connection.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to the German application No.10344361.4, filed Sep. 24, 2003, and to the International ApplicationNo. PCT/EP2004/009597, filed Aug. 27, 2004 which are incorporated byreference herein in their entirety.

FIELD OF INVENTION

The invention relates to an apparatus for communicating with a system,in particular for operating and monitoring an automation system inindustrial manufacturing.

BACKGROUND OF INVENTION

Input and output devices must be connected to industrial automationsystems in order to run said systems; this is known as processinterfacing. Output devices (monitoring devices) include e.g. checklights, alphanumeric or graphical displays, which inform the systemoperator about the current system state. Input devices (operatordevices) include e.g. switches, rotary knobs or keyboards foralphanumeric input, which allow the operator to act on the system.

SUMMARY OF INVENTION

In order to allow communication between user and system, so -calledoperator devices and monitoring devices, subsequently referred to simplyas communication devices, are usually installed permanently on thesystem itself or e.g. in the manufacturing hall where the system islocated. A typical communication device has a convenient casing in whichinput and output devices are arranged. The data interchange with thesystem or its control unit takes place via an interface cable which ispermanently installed.

Provision is also made for communication devices which are connected tothe system via a cable of greater or lesser length and allow mobilityfor the operator at or along the system within the limits of the rangeof the cable, wherein the operator can take the communication devicewith him or her.

In the case of very large or relatively inaccessible systems, cable-based communication devices are no longer practicable. Mobilecommunication devices, i.e. freely movable communication devices whichcommunicate wirelessly with the system and are battery powered, existfor this purpose and handle the data interchange with the system viaradio connection. So-called docking stations exist for this type ofcommunication device, e.g. in the form of a storage receptacle, and areused for housing the communication devices and charging the batterieswhich are present in the devices. The storage receptacles are locatede.g. near the system or in a separate area such as the supervisor cabin.

In order to set up a manufacturing process on a system, said system isfirst started in a running mode which is known as setup mode or learningmode. Fine tuning of the system is performed via the connectedcommunication devices in this context, e.g. the traverse paths of robotarms are configured. Communication devices which work in a wirelessmanner are normally only used during the setup mode, since here theoperator requires maximal mobility at the system in order to be able tomonitor and thus configure subprocesses accurately.

Once the manufacturing process has been set up on the system, the systemis switched into the normal mode, e.g. its production speed isincreased. During the normal mode, wireless communication devices arenot usually required or are even undesirable because they are batterydriven and therefore have only a limited service life or because theyplace an unnecessary load on the radio network of the system provider.The mobile communication devices are therefore stored away or, accordingto DIN, must even be locked away if they include safety-relatedfunctions (stop functions or permission functions). Communication withthe system during the normal mode then takes place via conventional,permanently installed communication devices, which often also havedifferent functionality, e.g. do not provide any specific functions forsetting up the system process.

Until now, therefore, different running states of the system haverequired different communication devices, and these must therefore beprocured concurrently. All communication devices must also be serviced,managed or programmed accordingly, thereby incurring significantexpenditure in terms of cost and effort.

The present invention addresses the problem of specifying an apparatusfor communicating with a system, wherein said apparatus is designed tobe less resource intensive and less costly.

The problem is solved by an apparatus for communicating with a system,in particular for operating and monitoring an automation system inindustrial manufacturing, which apparatus features a mobilecommunication device for wirelessly exchanging data with the system. Theapparatus also includes a connection interface for the communicationdevice, said connection interface being installed at a fixed location,and a sensor for detecting whether the communication device is connectedto the connection interface.

As a result of the mobile i.e. freely movable communication device,which includes wireless functionality, the system operator has maximalfreedom of movement at the system. In setup mode, the operator canfreely select an optimal location in order to check or adjust the systemfunction as effectively as possible.

Upon completion of the setup mode, the operator can connect thecommunication device to the connection interface which is installed at afixed location.

In this context, installed at a fixed location means that the connectioninterface has a permanent connection to the system and is assigned adefined location at the system. This can also include a service linefrom the system to the connection interface, said service line beingslightly flexible, such that the connection interface can be positionedin a user-friendly manner.

The sensor can be a light barrier, a proximity sensor or a contact loop,for example. It detects that the communication device is connected. Thesystem control unit is connected to the sensor and is capable ofanalyzing this information and also notifying the communication device.The connecting of the communication device can therefore serve as asignal, for example, in order to switch the system into the normal modeand to deactivate the setup-specific functionality at the communicationdevice.

It is therefore possible to influence the functionality of thecommunication device by utilizing the sensor information. For example,specific keys can be rendered inactive when the communication device isin the connected state, if said keys are only required for the setupmode. It is also possible for a graphical display on the communicationdevice to show other information depending on its connection state. Awide variety of possibilities are available here via the programming ofthe system or the control unit. The subsequent operation of the systemin the normal mode or manufacturing mode takes place using the samecommunication device, now connected to the connection interface, as wasused during the setup mode.

It is financially advantageous for the system provider that it is onlynecessary to invest in a single communication device, with which thesystem can be operated and monitored in all running modes. A furtheradvantage of the apparatus is that a defined position is established onthe system, namely the permanently installed connection interface, atwhich the communication device is connected during normal mode and isthere fore easy to find at any time. Therefore it is not necessary tolock the communication device away, since it is also intended for thenormal mode of the system.

Additionally, it might be necessary during normal manufacturing brieflyto switch the system into a correction mode which is similar to thesetup mode, in order to make post-adjustments to parts of the system,for example. This would previously have necessitated the reactivation ofthe separate communication device having wireless functionality, whereinsaid communication device would often have to be retrieved first fromthe place where it was stored.

If the claimed communication device is removed again from the connectioninterface, which action would be detected by the sensor, the systemswitches into a correction mode, for example. In this context, specificadditional functionality similar to that of the setup mode can beactivated on the communication device. In this way, it is possible toperform corrections on the live manufacturing and then simply reconnectthe communication device afterwards, without any additional expenditurein terms of devices or time. The system can then switch over tomanufacturing mode again.

The detection of the device connection by the sensor can also beutilized e.g. for checking whether all of the communication devicesavailable on the system have actually been reconnected to the intendedpositions at the end of a shift, for example.

In an advantageous configuration, the communication device features aninterface cable and the connection interface includes a cable connectioninterface for this interface cable. In comparison with the completefreedom of movement allowed when the communication device is notconnected, this allows the operator limited but nonetheless possiblemobility, within the limits of the interface cable, when operating andmonitoring the system even while the communication device is connectedand the system is e.g. in the normal mode. The sensor interacts with thecommunication device via the interface cable in this case. Of course,the interface cable can also be detachable from the communicationdevice.

The connection interface advantageously includes a storage location inwhich the communication device can be placed. As a result, there is adefined location at the system where the communication device can bestored for as long as it is connected. This avoids the need to place thecommunication device on an additional table or on the-ground, and theprecise position where it can be found is known. In this case, thesensor detects whether the communication device is inserted in thestorage location and is therefore attached to the system.

Furthermore, it is advantageous if the communication device is fixed inthe storage location in a lockable manner. When it is in the connectedstate, for example, it cannot then be stolen or removed by unauthorizedpersonnel, which would result in the system switching from themanufacturing mode into the setup mode or would allow the user to carryout settings or changes to the manufacturing processes by changing thefunctionality of the communication device. Any removal of thecommunication device is e.g. only possible using a key which is managedby the supervisor.

If the sensor is a switch which interacts with the communication deviceor its interface cable, it can be implemented in a manner with isparticularly easy, interference -proof and inexpensive.

In a particular embodiment, the apparatus features a data connectioninterface for wire-based data interchange between system andcommunication device. This can be integrated in the interface cable orthe storage location. In addition, the apparatus includes a changeoverunit for changing over between wireless and wire-based data interchange.According to the invention, the changeover of the data interchange cantake place in such a way that the process interfacing is notinterrupted. The data connection interface can also include anintegrated field bus coupling or even additional lines for safety-relevant functions, for example.

In general, wireless data interchange is always more interference-proneor unreliable than wire-based data interchange. Furthermore, radio modenormally requires greater energy expenditure, which must be provided bythe communication device, and e.g. in the above mentioned normal mode ofthe system the wireless data interchange is not usually required sincethe communication device is connected in this case. The changeover towire-based communication therefore results in communication which ismore reliable and less interference-prone and e.g. causes less EMCburden on the system from radio waves. The load on the radio network isalso reduced.

The apparatus is particularly advantageous if the sensor interacts withthe changeover unit in such a way that an automatic changeover towire-based data interchange takes place when the communication device isconnected to the connection interface. This ensures, for example, that achangeover to the less interference-prone wire-based data interchangealways takes place when the communication device is connected. Inaddition, the operator cannot forget e.g. to change over the type ofdata interchange manually.

In order to run the freely moveable wirelessly functioning communicationdevice, it must be equipped with a source of electrical energy. Anadvantageous development of the invention therefore makes provision forthe connection interface in the apparatus to include a power supply forthe communication device. This can again be integrated e.g. in theinterface cable or the storage location. As a result, the energy reservein the communication device is spared in the connected state, or caneven be recharged if it is an accumulator. This also ensures that, inthe connected state, the communication device has sufficient energy e.g.to run lighting at maximum brightness on the communication device.

BRIEF DESCRIPTION OF THE DRAWINGS

For a further description of the invention, reference is made to theexemplary embodiments in the drawings in which, by means of a blockdiagram in each case,

FIG. 1 shows a freely moveable wirelessly functioning communicationdevice in an industrial system in the unconnected state in the contextof wireless data interchange with the system, and

FIG. 2 shows the industrial system from FIG. 1 with the communicationdevice in the connected state in the context of wire-basedcommunication.

DETAILED DESCRIPTION OF INVENTION

FIG. 1 shows an automation system 1 including a permanently installedsystem part 2 and two mobile communication devices 3 a,b. The systempart 2 comprises a manufacturing machine 4, which is simply namedmachine 4 in the following, a control unit 5 which controls the machine4, and a radio station 6. The machine 4 is very large and cannot besurveyed from a single standpoint by an operator. A first connectioninterface 7 a is permanently attached, e.g. screwed on, at one end ofthe machine 4. Near to the other end of the machine 4, a secondconnection interface 7 b is attached e.g. to the wall of themanufacturing hall (not shown) in which the machine 4 is located. Sincethey are located in the manufacturing area of the system 1, theconnection interfaces 7 a,b are designed to be suitable for industrialuse, i.e. water-protected, dust-protected and mechanically robust.

The connection interface 7 a has a storage receptacle 24 which is usedfor holding the communication device 3 a, though this has been removedfrom the connection interface 7 a or storage receptacle 24 in FIG. 1.The connection interface 7 a includes a sensor 8 in the form of a switchand a data connection interface 9 a which, together with contacts 18 afor the power supply (usually 24 volts), is integrated in a connectioninterface socket 19 a.

The connection interface 7 b likewise comprises a sensor 8 and aconnection interface socket 19 a including data connection interface 9 aand contacts 18 a for a supply voltage. The connection interface 7 b isnot designed as a storage receptacle, however, but as a connectioninterface port or so-called access point which is suitable for use inindustry. A lock 25 which can be closed using a key (not shown) is alsoattached to the connection interface 7 b.

All components of the system part 2 are connected together via a fieldbus 10 for the purpose of data interchange. The data connectioninterface 9 a therefore provides a field bus coupling. Furtheradditional interface cables (not shown), e.g. having safety-relatedfunctionality, can be integrated in the connection interface socket 19a. The contacts 18 a are connected to the voltage network 20 of theautomation system 1.

The communication devices 3 a,b when used as input devices have pushkeys 11 by means of which the machine 4 can be operated via the controlunit 5, and when used as an output device have a display 12 on whichcurrent machine parameters of the machine 4 are displayed and by meansof which the machine 4 can therefore be monitored. Also attached to eachof the communication devices 3 a,b is a connection interface terminal 19b which corresponds to the connection interface socket 19 a and includesthe reciprocal contacts corresponding to the connection interface socket19 a, e.g. a data connection interface 9 b and contacts 18 b for supplyvoltages. The power supply for the communication devices 3 a,b in FIG. 1is provided by means of accumulators which are contained therein but arenot shown.

The communication devices 3 a,b differ by virtue of the connectioninterface terminals 19 b which are attached thereto. In the case ofcommunication device 3 a, the connection interface terminal ispermanently attached to the casing, whereas it is attached to aremovable contact unit 22 in the case of communication device 3 b. T hecontact unit 22 in turn is permanently connected to the communicationdevice 3 b via a flexible service line 23.

The communication between a communication device 3 a,b and the controlunit 5 takes place in each case along communication paths which areshown by the arrows 13 a,b. The communication paths 13 a,b initiallytravel between communication device 3 a,b and radio station 6 over radiosections 14 a,b which are formed between the antennas 15,16 on thecommunication devices 3 a,b and the radio station 6. At the radiostation 6, the communication data is converted from the antenna 16 tothe field bus 10 and transmitted via the field bus 10 to the controlunit 5.

The sensors 8 are connected to the control unit 5 via the field bus 10.The sensors 8, which are open because the communication devices 3 a,bhave been removed in FIG. 1, enable the control unit 5 to detect thatthe communication devices 3 a,b have been removed, i.e. are notconnected. In this running state, there is no connection bet ween theconnection interface sockets 19 a and the connection interface terminals19 b on the communication devices 3 a,b.

The utilization of the information from the sensors 8, i.e. that thecommunication devices 3 a,b have been removed, is freely programmable inthe control unit 5. In FIG. 1, the control unit 5 is programmed suchthat the machine is in setup mode as a result of the communicationdevices 3 a,b being removed. A different functionality may also bedesirable for other systems, however.

In the setup mode, as a result of the process interfacing to the machine4 via radio, an operator handling the communication device 3 a,b canfreely select an optimal position to occupy at the system part 2 orchange said position without restriction, and operate and monitor themachine 4 from there.

In FIG. 2, the communication devices 3 a,b are inserted in theconnection interfaces 7 a,b. As a result of this, the sensors 8 arepressed down and therefore in a closed position. By means of the sensors8, the control unit 5 detects that the communication devices 3 a,b areinserted and notifies the communication devices 3 a,b of this. Thisinformation can be used by the control unit 5 to now run the machine 4in the normal manufacturing mode, for example. The communication devices3 a,b can also e.g. change their functionality as a result of this, i.e.specific keys 11 can be rendered inactive or other machine parameterscan be indicated on the display 12, for example.

In FIG. 2, both communication devices 3 a,b are connected to (e.g.engaged in) their respective connection interfaces 7 a,b. In the case ofcommunication device 3 b, the contact unit 22 is separated from theactual device body and plugged into the connection interface 7 b. Whilethe communication device 3 a is now connected in a fixed location, thecommunication device 3 b is still mobile within the reach of its serviceline 23 although it is likewise connected. Therefore an operator of thiscommunication device 3 b still has room to move and can moreover, withincertain limits, choose his or her position in relation to the machine 4.The contact unit 22 is locked into the connection interface 7 b in FIG.2, since the lock 25 has been swung forwards and locked, using the key,against swinging back again. It is therefore impossible to removecontact unit 22 from the connection interface 7 b again without a key.

The connection interface sockets 19 a are connected to the connectioninterface terminals 19 b, thereby connecting the data connectioninterfaces 9 a and 9 b, the contacts 18 a and 18 b for the power supplyand any other lines which are included. The communication devices 3 a,bare therefore supplied with energy from the system part 2 via thevoltage network 20, and no longer require energy from their integratedaccumulators. These are recharged via the power supply, such thatsufficient energy is stored for the next radio mode as per FIG. 1. Inthis way, it is also possible e.g. to increase the brightness of theback-lit display 12 to maximal luminosity, since sufficient energy isavailable for this purpose from the power supply of the system part 2.In the accumulator mode according to FIG. 1, the brightness is usuallyreduced in order to save energy.

Since the control unit 5 is informed by the depressed sensors 8 that thecommunication devices 3 a,b are connected, the data interchange betweencommunication device 3 a,b and control unit 5 is changed over fromwireless to wire-based, and the antennas 15,16 are therefore not in use.The data traffic travels along the communication path 13 a,b which nowtravels from the communication device 3 a,b via the data connectioninterfaces 9 a,b and the field bus 10.

In order to change over between wire-based and wireless datainterchange, a changeover unit (not shown) is integrated in the controlunit 5, for example. This can be a program section of the controlprogram, but it can also be an actual switch. In the present case, thechangeover unit is linked to the sensors 8 in such a way that thechangeover takes place automatically as soon as the switch state of thesensors 8 changes.

The operation of the overall system 1 therefore continues to becoordinated using the same communication devices 3 a,b as in FIG. 1. Thechangeover from cable-based back to radio mode can take place at anytime during the running of the system 1, by removing the communicationdevices 3 a,b from the connection interfaces 7 a,b again.

Of course, it is also possible to remove only one communication device 3a or 3 b from the corresponding connection interface 7 a,b and tooperate only this communication device wirelessly while the othercommunication device 3 b,a continues to communicate in a wire-basedmanner with the control unit 5. The utilization in the control unit 5and in the communication devices 3 a,b of the information from thecorresponding sensors 8 in such a case must of course be adapted to theneeds of the production system 1 concerned.

1. An apparatus for communicating with a system, comprising: a mobilecommunication device for wirelessly exchanging data with the system; astationary connection interface for accommodating and connecting themobile communication device to the system; a sensor for detectingwhether the mobile communication device is connected to the stationaryconnection interface; and a system control unit, wherein the systemcontrol unit is connected to the sensor for analyzing the detecting bythe sensor, wherein a functionality of the mobile communication deviceis changed when the mobile communication device is connected to thestationary connection interface such that the functionality of themobile communication device chances from a setup mode or a correctionmode into a normal mode deactivating the setup-specific functionality,the setup mode or correction mode being used for wirelessly configuringor adjusting the system.
 2. The apparatus as claimed in claim 1, whereinthe system is an operating and monitoring system of an automation systemused in industrial manufacturing.
 3. The apparatus as claimed in claim1, wherein the mobile communication device includes an interface cable,and the stationary connection interface includes a cable connectioninterface for accommodating the interface cable.
 4. The apparatus asclaimed in claim 1, wherein the connection interface includes a storagelocation for accommodating the mobile communication device.
 5. Theapparatus as claimed in claim 1, wherein the mobile communication deviceis fixed to the stationary connection interface using a detachable lock.6. The apparatus as claimed in claim 1, wherein the sensor is a switchconfigured to interact with the mobile communication device.
 7. Theapparatus as claimed in claim 3, wherein the sensor is a switchconfigured to interact with the interface cable.
 8. The apparatus asclaimed in claim 1, further comprising: a data connection interface forestablishing a wire-based data exchange between the system and themobile communication device; and a selector unit for changing overbetween wireless and wire-based data exchange.
 9. The apparatus asclaimed in claim 8, wherein the sensor is configured to interact withthe selector unit such that the changing over to wire-based dataexchange is executed if the mobile communication device is connected tothe stationary connection interface.
 10. The apparatus as claimed inclaim 1, wherein the stationary connection interface includes a powersupply for supplying the mobile communication device when connected tothe connection interface.